Patent Application
20130125493
1. Technical Field
This invention relates generally to the technical field of wall repair, and in particular to the field of patching and repairing damaged walls, including drywall, foam board, particle board, and the like.
2. State of the Art
The use of drywall became popular after the 1950s. Since then, a variety of techniques and methods have been developed for patching and repairing damaged drywall areas. Conventional drywall patching and repair devices, such as repair clips and other like fasteners available on the market today, are typically metallic and require screws or teeth to secure them.
The table below lists common patents in the field, including U.S. Patent Numbers, corresponding Issue dates and Inventor Names.
All the methods and techniques developed in the past have advantages and disadvantages compared to the each other; with each device having its own distinct but similar method. The conventional way of repairing drywall generally works, but in some cases is expensive, time consuming, cannot be applied everywhere and requires a lot of labor. One example of difficulty in using such devices is if drywall size or thickness is different from the one specified in the device's specifications. This discrepancy could lead to unexpected problems and frustration.
Furthermore, it is not an uncommon experience to realize that the device cannot be used for every kind of drywall damage. Therefore, conventional devices do not provide a universal use for every type of drywall or board and every type of damage. Conventional devices are thus themselves a limitation to repair.
There is thus a need in the industry for a device that addresses the problems discussed above. Attempts have been made in the past to address these problems, but none of them can be compared with the present invention as herein described.
The present invention relates generally to the technical field of wall repair, and in particular to the repair and/or patching of damaged walls, i.e., drywall, foam board, particle board, and the like.
An aspect of the present invention comprises a drywall patch piece apparatus and attaching the apparatus to a damaged drywall section by use of a plastic adhesive fastener from behind the drywall (inside of the hollow wall) not from the visible side (room side of the wall). Utilizing the apparatus, the damaged drywall can be repaired and patched, as will be herein described. The apparatus is for users to repair any kind of drywall damage in any location, any shape, any size and any thickness. It is a universal device and can be used for repairing other types of boards and panels including but not limited to foam board, particle board, pressed board, and fiberglass board. In addition, it can be used as a fastener to join two objects from the rear by adhesive and leave no sign of joining on the front surfaces. Another advantage of the present invention drywall patch fastener is that it is non-intrusive to the hidden (back) surface of the drywall under repair.
Yet another aspect of the present invention is that it is non-intrusive to any and all objects and materials inside the wall such as wiring, plumbing, and insulation.
Yet still another aspect of the present invention is that it is made of plastic which is cost efficient for the consumer and manufacturer. Also, it will not rust in storage or cause damage when it is used in the wall, even if the surrounding environment is very corrosive.
Yet still another aspect of the present invention is that it can be used without any screws, although hole guides are still available to accept screws if necessary.
Yet still another aspect of the present invention is that it does not require any professional tools or any specific household tools.
Yet still another aspect of the present invention is that installation is very simple allowing most individuals to use the device. Installation does not require the hire or experience of a professional person. Therefore, the invention can be used by a professional or by the common public.
The foregoing and other features and advantages of the present invention will be apparent from the following more detailed description of the particular embodiments of the invention, as illustrated in the accompanying drawings.
a is top view of a component of the wall repair apparatus in accordance with the present invention.
b is a side view of the component of the wall repair apparatus shown in
a is a front view of the wall shown in
b is a front view of a patch piece cut to fit within the portion of the wall that has been removed, as shown in
a is a dimensional view of the component shown in
b is a dimensional view of the component shown in
As discussed above, embodiments of the present invention relate to the technical field of wall repair, and in particular to the repair and/or patching of damaged walls, i.e., drywall, foam board, particle board, and the like.
As shown in
In further detail, the wall repair apparatus 100 can generally made of a plastic such as Nylon 6,6 (6/6), but the apparatus 100 is not limited to being made of plastic. Indeed, the apparatus 100 can be made of any suitable material that provides the structural characteristics that are herein described. Both the first piece 10 and the second piece 20 can be square, rectangular or any other shape that provides the characteristics of the present invention that are herein described. One such dimension for both the first piece 10 and the second piece 20 is 40 mm×40 mm (1.5 inch×1.5 inch), but, as mentioned above, the first and second pieces 10 and 20 are not be limited to these specific dimensions. The securing member 30 can be, for example, but not limited to, a conventional cable tie, such as 3M® Part No. PLT1.5S-M, having dimensions of 5 mm×152 mm, but the securing member 30 may be any device suitable for securing pieces 10 and 20 relative to one another, as is herein described.
The first piece 10, the second piece 20 and the securing member 30 are components that are to be manufactured and are specific components of the present invention and will be discussed in details below.
Shapes, size, color and type of material mentioned herein for the first piece 10, the second piece 20, and the securing member 30 are just for ease of understanding.
The actual manufactured components 10, 20 and 30 can be in many sizes, for instance ½ in, ¾ in, 1 in, 1½ in, 2 in etc. with many color options and may be manufactured from different type of plastics or other materials. Also, the actual shape of components 10, 20 and 30 may change according to the molding and manufacturing process.
The first piece 10 may comprise a body 16, a reception housing 17, and strengthening member 19. The body 16 may be a flat, plate-like piece that has a front surface 16-1 and a back surface 16-2. The reception housing 17 may be a cube-like body mounted to the back surface 16-2 of the body 16. The housing 17 may be further comprised of a reception hole 11, wherein the securing member 30 can be inserted therethrough. The strengthening members 19 run along the back surface 16-2 of the body 16 from the corners, or edges, of the housing 17 to the corresponding corners, or edges, of the body 16. The strengthening members 19 may taper from the housing 17 to the edges of the body 16. The strengthening members 19 function to enhance the stability of the body 16 and enhance the rigidity of the body 16, or in other words, increase the mechanical strength of the first piece 10.
The body 16, the housing 17, and the strengthening members 19 can be manufactured separately and thereafter coupled together, the housing and the strengthening members being attached to the back surface 16-2. Alternatively, the body 16, the housing 17, and the strengthening members 19 can be integral, meaning they can be formed of one single piece.
The reception hole 11 is configured to releasably couple to the securing member 30 at predetermined intervals along the securing member 30. The housing 17 can therefore assume any configuration that allows the reception hole 11 to function to releasably couple to the securing member 30. The body 16 may further be comprised of one strengthening member 19 or a plurality of strengthening members 19, as desired during manufacturing or assembly.
The body 16 can be manufactured to specific dimensions of 40 mm (length)×40 mm (width)×3 mm (depth). However, the body 16 can be manufactured to whatever dimensions chosen, as long as the body 16 is large enough to receive the securing member 30 and be able to be releasably coupled thereto. Moreover, the body 16 must be large enough to adhere to both a back surface 41 of a wall 40 to be repaired and a back surface 51 of a patch piece 50 that will be inserted into an opening 46 cut into the wall 40, and support the patch piece 50 within the opening 46. Specifically, the front surface 16-1 is comprised of a flat surface, the flat surface being square, rectangular, or any shape that allows an adhesive 14 to be attached thereto such that the adhesive 14 can secure the body 16 to the wall 40 and patch piece 50, as will be described in detail below.
The housing 17 may be manufactured to dimensions of 15 mm (height)×15 mm (width)×5 mm (depth). As mentioned above, the housing 17 can alternatively have any dimensions that permit the reception hole 11 to function to releasably couple to the securing member 30. The outer surface of the housing 17 is surface 18.
The front surface 16-1 of first piece 10 has attached thereto the foam-type double-coated adhesive 14, mentioned above. An exemplary adhesive may be 3M™ part number 4004 for sticking to drywall surfaces. The adhesive 14 should distribute stress uniformly over its surface area once bonded to another surface. A backing paper 15 covers and protects the adhesive 14 until the adhesive is needed for use. The backing paper 15 can be peeled from the foam-type double-coated adhesive 14 at the time of use to be applied and the exposed adhesive can stick to the back surface 41 of the wall 40. Initially, the adhesive 14 should adhere to the front surface 16-1 on one of its sticky sides and the backing paper 15 should prevent the opposing sticky side from adhering to anything but the backing paper 15. Once the backing paper is removed, the exposed sticky side can be adhered to any surface desired by the user, preferably the back surface 41 of the wall 40.
The reception hole 11 passes through the first piece 10 from the surface 18 to the surface 16-1, including through the adhesive 14 and the backing paper 15. The reception hole 11 has a dimension of 9 mm (length)×2.5 mm (width) and is configured to correspond to the shape and size of the securing member 30, such that the securing member 30 can be inserted therethrough and establish functional coupling thereto.
As shown in
As shown in
The reception hole 21 is configured to receive the securing member 30 and have the securing member 30 slide therethrough. The reception hole 21 and the securing member 30 are configured to releasably couple to one another at successive intervals along the securing member 30, once the securing member 30 has been inserted into the reception hole 21. Thereafter, the second piece 20 can be advanced along the securing member 30 by force toward the first piece 10, but cannot retreat along or release from the securing member 30 until the release lever 23 is operated, thus allowing the second piece 20 to be removed from the securing member 30. It follows that without operating the release lever 23, the second piece 20 will remain coupled to the securing member 30 to thereby fasten an object between the second piece 20 and the first piece 10. As applied to the instant invention, the wall 40 and the patch piece 50, for example and not as a limitation, may be secured between the first piece 10 and the second piece 20 by the securing member 30 and the interaction between the securing member 30 and the first and second pieces 10 and 20, respectively.
The body 26, the housing 25, the strengthening members 27, the finger grip 24, and the release lever 23 can be manufactured separately and thereafter coupled together, the housing 25 and the strengthening members 27 being attached to the back surface 26-2, the finger grip 24 being attached to the housing 25, and the release lever being coupled to one of the finger grip 24 and housing, or both. Alternatively, the body 26, the housing 25, the strengthening members 27, the finger grip 24, and the release lever 23 can be integral with one another, meaning they can be formed of one single piece.
The body 26 can be manufactured to specific dimensions of 40 mm (length)×40 mm (width)×3 mm (depth). However, the body 26 can be manufactured to whatever dimensions chosen, as long as the body 26 is large enough to receive the securing member 30 and be able to be releasably coupled thereto. Moreover, the body 26 must be large enough to engage both the wall 40 to be repaired and the patch piece 50 that will be inserted into the opening 46 cut into the wall 40, and thereafter secure the patch piece 50 within the opening 46. Specifically, the front surface 26-1 is comprised of a flat surface, the flat surface being square, rectangular, or any shape that allows front surface 26-1 to engage both the wall 40 and the patch piece 50 while the second piece 20 is coupled on the securing member 30 and advanced to the wall 40 and patch piece 50, as will be described in detail below.
The housing 25 may be manufactured to dimensions of 15 mm (height)×15 mm (width)×5 mm (depth). As mentioned above, the housing 25 can alternatively have any dimensions that permit the reception hole 21 to function to releasably couple to the securing member 30. The outer surface of the housing 25 is surface 28.
As shown in
The reception hole 21 passes through the second piece 20 from the surface 28 to the surface 26-1. The reception hole 21 has a dimension of 9 mm (length)×2.5 mm (width) and is configured to correspond to the shape and size of the securing member 30, such that the securing member 30 can be inserted therethrough and engage the reception hole 21.
As shown in
The securing member 30 is a length of material that has an integrated gear rack thereon, similar to a standard cable tie. The securing member 30 may have dimensions of 5 mm (width) and a length of between about 100 and 300 mm. The securing member 30 has a head at one end of the securing member 30, which prevents the securing member 30 from be pulled entirely through the first or second pieces, 10 and 20, respectively. Standard cable ties are available in hardware stores and can be used as the securing member 30 of the present invention. If a standard cable tie is to be used as the securing member 30, the reception holes 11 and 21 must have a corresponding ratcheting system configured therein to engage the integrated gear rack of the securing member 30. As the securing member 30 is inserted into the respective reception holes 11 and 21, the ratcheting system engages the integrated gear rack to allow the first piece 10 and the second piece 20, respectively, to advance on the securing member 30. The interface between the ratcheting system and the integrated gear rack forbids the first piece 10 and the second piece 20 from retreating along the securing member 30 once advanced. An exemplary securing member 30 can be Panduit® part number PLT1.5S-M, which is 177 mm (length)×4.8 mm (width) (or 6.2 in×0.19 in).
Hereinafter, a method of using the apparatus 100 will be described in detail. Imbedding the patch piece 50 in the wall 40 is one of the unique advantages that the current invention offers over conventional devices.
The apparatus 100 is operated by imbedding a patch piece 50 in the hold of the wall 40 to be repaired and holding the patch piece 50 firmly in place by adhesive 14 on the first piece 10 fastened to the inside surface 41 of the wall 40 and not from the visible outside surface of the wall 40. By using the method of the present invention the surface of wall 40 and imbedded drywall patch piece 50 will be smooth and aligned and will be covered with drywall compound easily and quickly because the only thing to cover is a small gap 60 between the wall 40 and the imbedded drywall patch piece 50.
Referring now to
Referring now to
The step of placing the first piece 10 to the inner surface 41 of the wall 40 is repeated until a plurality of first pieces 10 are attached to the inner surface 41 at regular intervals, such that portions thereof are exposed in the opening 46 at user determined distances. In particular, as shown in
Referring now to
Referring now to
As illustrated in
Referring now to
As mentioned above, the notch 22 in upper half and lower half of the second piece 20 accommodate passage of the drywall screw 61 to be screwed through the wall 40 and patch piece 50 into the first piece 10. The drywall screw 61 does not engage or hold the second piece 20 to thus allow the second piece 20 to be removed, as describe below.
Referring now to
Referring now to
Referring now to
The advantages of the present invention include, without limitation, that it is exceedingly easy to use, time-saving, provides a nice and clean finish, leaves no humps or bumps on the wall surface, aligns the wall surface with the embedded drywall patch piece, and leaves but a small gap between the wall and the embedded drywall patch piece to be filled with drywall compound and taped. After finishing, the final appearance is like no repair job was done on the wall.
Although the present invention can be made of any material suitable for its intended purpose, using plastic provides advantages including there are no sharp edges to hurt the user and no metallic components to rust in the wall or during storage. Moreover, plastic is a very good candidate to be used in humid environments. Plastic is lightweight, resulting in both lower shipping costs and negligible weight on the wall or ceiling during and after installation. Further, the present invention is not intrusive to the material and utilities inside the wall and environment.
The embodiments and examples set forth herein were presented in order to best explain the present invention and its practical application and to thereby enable those of ordinary skill in the art to make and use the invention. However, those of ordinary skill in the art will recognize that the foregoing description and examples have been presented for the purposes of illustration and example only. The description as set forth is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the teachings above without departing from the spirit and scope of the forthcoming claims.
